Apparatus for cell construction



Nov. 19, 1963 J. v. CARLISLE ETAL 3,110,970

APPARATUS FOR CELL CONSTRUCTION Filed Nov; 21, 1960 2 Sheets-Sheet 1 IN VE N T0 RS JAMES M CA RL/SLE #1500095 u. ARA/0L 0 ATTORNEY Nov. 19, 1963 J. v. CARLISLE ETAL 7 APPARATUS FOR CELL CONSTRUCTION Filed Nov. 21, 1960 2 Sheets-Sheet 2 IN VEN TORS JAMES M. CARL/SL5 BY THEODORE M. ARNOLD A 7' TORNE Y United States Patent C) 3,11%,973 APPARATUS FOR CELL CGNSTRUCTEQN James V. Carlisle, Baton Rouge, La., and Theodore M.

Arnold, Punta Gorda, Fla, assignors to Ethyl Corporation, New York, N.Y., a corporation of Virginia Filed Nov. 21, 196%), Ser. No. 70,8d2 2 Claims. ((31. 33-1930) This invention relates to a new and novel method for the construction of electrolytic cells, and in particular it relates to apparatus used for the construction of these cells.

This is a continuation-in-part of co-pending application Serial No. 715,171, filed January 30, 1958, which in turn was a co-pending division of application Serial No. 493,156, filed March 9, 1955, the latter now issued US. Patent 2,912,750.

The manufacture of sodium and other alkali metals is carried out in an electrolytic cell basically similar to the Downs cell described in US. Patent 1,501,756. Briefly, the cell includes a housing containing one or more cylindrical anodes each of which is projected into openings contained within, or is in other words surrounded by a cylindrical cathode. In the annular space which is formed between an anode and the surrounding internal surface of the cathode is positioned a foraminous diaphragm supported from above by a collector. The collector, a unitary assembly, includes an outlet port for removal of the gaseous halogen, and also an annular inverted channel for manifolding and for the rem-oval of the alkali metal. This collector is supported by a frame which in turn is attached to and supported by the cell housing.

The concentricity and vertical disposition of the surfaces of the anodes with the surrounding diaphragm and surrounding cathode surface is an important attribute of a properly constructed cell. Attaining this objective has been a long standing problem in the industry. Inherent difficulties in the construction of these cells has been the lack of a suitable method -for positioning the cathode with respect to the anode, and for positioning the diaphragm within the annular space between anode and cathode. Because the cathode and the diaphragm surround substantially the entire length of the anode, it is quite difficult to position the diaphragm concentrically between the cathode and anode within proper tolerances so as to provide a cell capable of the most eflicient operation. The difiiculty in maintaining concentricity between anode, cathode and diaphragm can be appreciated when it is noted that ordinarily the lateral distance beween the anode and cathode is of the order of only 1 /2 inches as compared with the entire length of the anode, which is about 3 to 4 feet or more in length. In addition, for best operation the diaphragm must be inserted equidistant from the anode and cathode over the entire length of the anode. Prior methods employed for achieving this result have not been adequate. Generally speaking, the life period, that is the time period of operation before the cell need be broken down for rebuilding, has been erratic and necessitated completely dismantling the cell to replace the diaphragms. Such dismantling and reconstruction, in addition to being inherently expensive, also results in reducing production capacity of a plant. This arises from the fact a shop or plant has a certain number of stalls or locations for occupancy by as many cells; when a cell is being torn down and rebuilt, it is then not possible to merely insert a spare into that operating space.

Until the present invention, the techniques in cell building left much to be desired, as above explained. Consequently, it is an object of the present invention to provide apparatus for the rapid and accurate construction of an electrolytic cell. A further object of this invention is to provide apparatus to be employed in constructing an electrolytic cell which will provide a cell having a longer life, higher eficiency, and increased productivity. Another object of the present invention is to provide apparatus for the accurate positioning of a cathode assembly upon an anode-cell base assembly. A particular object is to provide apparatus for positioning and assembling a cathode upon an anode-cell base so that cathode and anode are concentric one with respect to the other. Other objects will be apparent from the discussion hereinafter.

The apparatus of the present invention is capable of assuming a variety of forms, and can be used in conjunction with other apparatus, as will be readily understood from the details given hereinafter and in the accompanying figures wherein,

FIGURE 1 shows in exploded fashion the major components of a cell, the sequence of assembly of the components into a completed cell, and the relation of the apparatus of the present invention to other apparatus and to the several major components or sub-assemblies of a cell, and

FIGURE 2 is an isometric, partially sectioned view of a jig apparatus, termed herein as Jig D, for positioning the cathode of a four anode cell with respect to the previously positioned cell anodes, the anodes and cathode being shown in operative relationship.

The apparatus employed for the positioning and aligning of a unitary cathode assembly, having a plurality of cylindrical openings, upon a plurality of anodes, pursuant to the present invention comprises a frame or generally planar member upon one side of which is mounted, at right angles, a plurality of hollow cylindrical guides or tubular members, each having internal openings corresponding in diameter to the diameter of an anode. The external diameter of each of the guides are intermediate the diameters of the anodes and the cathode cylindrical openings. These guides, corresponding in plan and number with the anodes of a completed. cell, mate snugly with the anodes. The apparatus is further provided with alignment and leveling means for precise horizontal and vertical alignment of the entire apparatus, and particularly for the alignment of the guides upon which the cathode, or cathode cylindrical openings, are laterally and vertically aligned.

It has been found that the apparatus of this invention, particularly in combination with other apparatus, provides an efficient means for the construction of an electrolytic cell whereby the criticality of the positioning of the cathodes with respect to the anodes, and the diaphragms with respect to the cathode and anodes, is achieved. The apparatus eliminates incorrect alignment of these integral parts which results, for example, in burning of the diaphragrns and thus causing loss or" production and unnecessary dismantling of the cell, which must be reconstructed. By the use of the apparatus of this invention, the efliciency of the cell is considerably increased as evidenced by the fact that production is increased for a given current input. In addition, the average life of the diaphragm is appreciably increased, thereby reducing loss in production time.

The construction of a completed cell includes two major asembly sequences, the assemblies so-made being combined into a completed cell. One sequence of assembly operations permits formation of the lower portion of a cell. This sequence of operations thus provides for the formation of a complete base assembly by the addition of anodes to a cell base, then for the addition of a cell shell portion, then for the addition of a cathode, then for the addition thereof of an upper or final cell shell portion, thus completing this major assembly.

Another sequence of assembly operations includes assembly of a collector and collector support frame to form a sub-assernbly, and then the additoin of diaphragm screens to that sub-assembly to form the upper portion of a cell, the second of the two major assemblies. These two assemblies are then combined to form a completed cell.

This entire sequence of assembly operations is schematically illustrated by reference to FIGURE 1 which shows the flow of separate cell components into subassemblies and the relationship of these components and sub-assemblies to the figures of the present invention. Referring to FIGURE 1, a set of anodes and a cell base are combined, using Jig C. The base assembly thus formed is then combined with a cell shell portion. A part of the cell lining is then added, and a cathode is then fitted to this base sub-assembly using. a Jig D to provide proper spatial relations. To this assembly is then added an upper cell shell using Jig E for correct alignment. This sequence of operations completes the formation of one of the two major assemblies, viz., the formation of a complete base assembly, or the lower portion of a cell.

The other major sequence of assembly operations involves firstly the combination of a collector and collector support frame into a sub-assembly, using Jig A. This sub-assembly and a set of diaphragms are then combined by the use of another apparatus, Jig B. This completes the second major sequence of operations and provides for the formation of a collector-collector frame-diaphragm assembly, the upper portion of a cell. This assembly is then transported in a transport Jig F and is combined with the base assembly to form a completed cell.

The apparatus, Jig D, employed for positioning the cathode of a cell with respect to the anodes of a previously formed anode-base assembly, shown in FIGURE 1, is described by reference to FIGURE 2. FIGURE 2 shows in detail, Jig D, which is used for the accurate positioning of the cathode with respect to the anodes. Referring to FIGURE 2, this is a partially sectioned elevation showing the previously positioned anodes, such as 131 r 131 131 and a cathode unit 141 in operative relation with Jig D. The Jig D includes a frame member 142 and four cylindrical guides, such as 143 143 14 3. Segments of the lower and upper cell shell 148 and the refractory lining .149 within the cell shell 148 are also shown.

The jig frame 142 is rigidly reinforced by cross members 144 and a rim 145. Four pillow blocks 145 14 6 146 146 are mounted on the jig frame 142, and on the pillow blocks 146 are accurately positioned alignment or supporting bosses 147 147 1.47 147 The cylindrical guides 143 are rigidly attached to the jig frame 142 at precise right angles to the plane of the frame 142. In plan position, the centers of the cylindrical guides define a square having the same dimensions as the square defined by the centers of the cell diaphragms located upon a collector-collector support frame-diaphragm sub-assembly. The internal diameter of the guides 1 43 is equal or substantially equal to the diameter of the anodes 131, thus allowing a snug slip fit over the anodes. The external diameter of the guides is less than the internal diameter of the cathode segments. Accordingly a gap is provided between the anode 131 and guides 143, and between the guides 143 and the cathode 141.

A levelinig device 151 is rested on the jig frame 142 and includes two level glasses 152 152 angularly positioned so that accurate horizontal disposition of the Jig D and hence the vertical positioning of the anodes is obtainable. In addition, in properly locating the cathode 141 with re- .spect to the anodes 1311, this alignment, as described below, permits establishment of a horizontal reception base for subsequent addition of the collector-collector support frame-diaphragm assembly. The horizontal check provided with the Jig D is also further required in those cases wherein a cell base is assembled, with the aid of Jig C,

in a location separate and remote from the final intended cell location.

A plurality of openings 153 are provided in the Jig D for lateral alignment of the cathode unit 14-1 after horizontal alignment is provided. One set of openings 153 is positioned above the annular spaces between the cathode 141 and the cylindrical guides 143. Another set of openings 154 is provided for sighting, inspection, and lightening. In obtaining lateral alignment, feelers not shown are inserted in the cathode-guide annular spaces and the cathode unit laterally shifted as necessary to provide uniform anmdar spaces.

With the proper spatial relationship established between the anodes 1&1 and the cathode unit 141, the cell lining M9 can be built up around the cathode arms 14% to immobilize and permanently position the cathode unit 141.

The next step in the construction of a shell is the positioning and attachment of an upper cell shell surmounting the lower cell shell already referred to, and the establishment of reference marks having a defined spatial relationship to the previously established anode-cathode configurations. The lower portion of a cell thus completed is then ready for assembly with an upper cell assembly to form a complete cell.

From the foregoing, it is seen that the use of various apparatus provides for the construction of a cell having a continuous explicit relationship between the collector frame, collector, diaphragm, anodes, and other portions of a cell. These relationships are established and preserved from the beginning of construction through to the final assembly step. tFurther steps to render a cell operable after assembly of a complete base assembly with a collector-collector frame-diaphragm assembly would include the connection of an appropriate chlorine line to the collector opening, and the attachment of the necessary electrical connections, etc.

In careful comparison of the performance of a group of cells constructed with the apparatus of our invention with performance of a group constructed according to previous methods it was found that the former group provided an increase of approximately 1.5 percent in current eh ciency. In addition, it was found that the average effective life of the former group of cells was a significant improvement over the preceding practice, particularly with respect to the diaphragm life. Since the cost of construction of cells with the present apparatus is substantially the same as by the former practices, it is apparent that our appartus is highly beneficial and economical.

Having described the apparatus of our invention in some detail and the manner of its use, what we claim is:

We claim:

1. Apparatus for the alignment of a cathode assembly consisting of a unitary member having a plurality of cylindrical openings and arms for mounting above the anode-cell sub-assembly of a cell comprising a planar frame upon which is vertically mounted a plurality of tubular guide members arranged in plan corresponding to that of the anodes of the cell base and with the plan of the cathode cylindrical openings which form walls, the tubular members providing openings of diameters intermediate those of the anodes and the cathode openings a plurality of openings within the frame between the tubular members for lateral alignment of the cathode, a leveling device including two level glasses positioned upon the frame at right angles to each other so that the accurate horizontal disposition of the apparatus and hence the vertical positioning of the anodes is obtainable whereby the said apparatus provides for gaging and laterally aligning the cathode assembly with the anodes such that uniform concentric annular openings are pnovided between the anodes and the cylindrical openings of the cathode assembly, and also provides a horizontal reception base for subsequent mounting of the collector-collector support frame-diaphragm sub-assembly.

2. Apparatus for laterally and vertically aligning a 5 unitary cathode assembly, having a plurality of cylindrical openings, upon a plurality of vertically aligned anodes comprising a planar frame upon one side of which is mounted, at right angles, a plurality of cylindrical guides corresponding in number and plan with the anodes, said guides having internal diameters corresponding in size with the diameter of an anode and external diameters intermediate the diameter of an anode and cathode cylindrical opening, a plurality of openings within the frame between the tubular members for lateral alignment of the cathode, the frame of said apparatus being provided with two level glasses at right angles to each other for determining accurately the horizontal disposition of the apparatus frame whereby the cathode can be laterally and vertically oriented upon the anodes.

References Cited in the file of this patent UNITED STATES PATENTS 1,763,115 Werm-ine June 10, 1930 2,531,799 Zumwalt Nov. 28, 1950 2,536,677 Brunner et a1. Jan. 2, 1951 2,768,431 Hughes Oct. 30, 1956 2,779,021 Swarzman Jan. 29, 1957 2,970,367 Crump Sept. 3, 1957 

1. APPARATUS FOR THE ALIGNMENT OF A CATHODE ASSEMBLY CONSISTING OF A UNITARY MEMBER HAVING A PLURALITY OF CYLINDRICAL OPENINGS AND ARMS FOR MOUNTING ABOVE THE ANODE-CELL SUB-ASSEMBLY OF A CELL COMPRISING A PLANAR FRAME UPON WHICH IS VERTICALLY MOUNTED A PLURALITY OF TUBULAR GUIDE MEMBERS ARRANGED IN PLAN CORRESPONDING TO THAT OF THE ANODES OF THE CELL BASE AND WITH THE PLAN OF THE CATHODE CYLINDRICAL OPENINGS WHICH FORM WALLS, THE TUBULAR MEMBERS PROVIDING OPENINGS OF DIAMETERS INTERMEDIATE THOSE OF THE ANODES AND THE CATHODE OPENINGS A PLURALITY OF OPENINGS WITHIN THE FRAME BETWEEN THE TUBULAR MEMBERS FOR LATERAL ALIGNMENT OF THE CATHODE, A LEVELING DEVICE INCLUDING TWO LEVEL GLASSES POSITIONED UPON THE FRAME AT RIGHT ANGLES TO EACH OTHER SO THAT THE ACCURATE HORIZONTAL DISPOSITION OF THE APPARATUS AND HENCE THE VERTICAL POSITIONING OF THE ANODES IS OBTAINABLE WHEREBY THE SAID APPARATUS PROVIDES FOR GAGING AND LATERALLY ALIGNING THE CATHODE ASSEMBLY WITH THE ANODES SUCH THAT UNIFORM CONCENTRIC ANNULAR OPENINGS ARE PROVIDED BETWEEN THE ANODES AND THE CYLINDRICAL OPENINGS OF THE CATHODE ASSEMBLY, AND ALSO PROVIDES A HORIZONTAL RECEPTION BASE FOR SUBSEQUENT MOUNTING OF THE COLLECTOR-COLLECTOR SUPPORT FRAME-DIAPHRAGM SUB-ASSEMBLY. 